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Powerhold Owner`s/User Manual

1. Item Quantity Part Number Description A 2 2101 0039 Nylon Lock Nut 5 16 18 UNC B 2 9301 0029 Seal Thread C 1 9302 0014 Reservoir D 1 9301 0199 Breather Cap 3 8 NPT Male E 1 9301 0027 O Ring Reservoir F 2 9302 0012 Tie Rod Reservoir 1 9301 1 Pump Only G 4 2101 0016 Cap Screw 5 16 18 UNC x 3 1 2 in Grade 5 1 9301 0028 Gasket Pump 1 9303 0002 Coupling Assembly H 1 9302 0017 Plate Drive J 1 9904 0001 Hose K 1 0521 0017 90 Elbow 3 8 NPT Male x 8 JIC Male L 1 0521 0007 90 Elbow 1 4 NPT Male x 1 4 Tube M 1 3411 2 Motor Only N 1 0521 0015 Straight Fitting 3 8 NPT Male x 8 JIC Male P 1 0521 0014 Ball Check Q 1 9301 0024 Guide Check Ball H 1 9302 0009 opring Relief Valve S 1 9303 0003 Screw Adjusting T 2 9301 0014 Washer Nylon 11 16 in OD x 1 2 in ID U 1 9301 0015 Nut Jam 1 2 20 UNF V 1 9301 0016 Nut Acorn 1 2 20 UNF W 1 0521 0016 45 Elbow 3 8 NPT Male x 8 JIC Male X 1 9301 0009 Strainer Suction Y 1 9301 0082 Magnet Z 1 9301 0008 Pipe Nipple 3 8 NPT x 3 in AA 2 9301 0003 Washer Aluminum 9 16 in OD x 3 8 in ID x 1 16 in AB 2 9301 0004 Screw Socket Head 3 8 16 UNC x 1 3 4 in AC 2 2101 0063 Nut Jam 5 16 18 UNC 1 9395 Power Pack Complete Includes All Items Except L N and W 1 Provide dock leveler serial number and type of installation when calling or faxing orders Provide dock leveler serial number voltage and phase when callin
2. ff E x SS N E y q PE d SS PES S S SS Y 1 m 5 Re E P ho y N EM is 7 No adjustments required o E Prox Switch PRS 2 EE INPUT 4 1 16 min EE Install prox flush then back out 1 8 max m CCW just past flush 1 Prox Switch PRS 1 INPUT 3 The Operating range is not adjustable on a IMPORTANT Make sure that the wire from the prox PowerHold restraint switches are clear of all moving parts Proximity switch Adjustment and replacement A Locate and remove four screws and cover on front of PowerHold assembly B Adjust PRS 1 With the Z bar rotated directly over the prox switch The prox switch distance should between 1 16 and 1 8 C Adjust PRS 2 The 2 prox switch must be threaded in until flush with the latch block Turn prox switch out CCW until switch is no longer flush with the latch block 4111 0016 January 2014 23 OPTIONAL EQUIPMENT ADJUSTMENTS Adjust Dock Leveler and Vehicle Restraint Interlock When service under the dock leveler is required always lock all electrical disconnects in the OFF position after raising the platform and engaging the maintenance prop Failure to do this may result in serious personal injury or death Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete Failure to do this may result
3. In addition to the Standard Product Warranty provided with all Poweramp Products Systems Inc guarantees materials components and workmanship to be free of defects for the following extended periods e Structural Warranty For a period of five 5 years from the date of shipment this warranty specifically applies to restraint shoe pivot pin and frame weldment only e Hydraulic Warranty For a period of two 2 years from date of shipment this warranty specifically applies to the hydraulic pump and motor all hydraulic cylinders hydraulic pressure lines fittings and valves only Electrical Warranty For a period of two 2 years from date of shipment this warranty specifically applies to the control box components proximity switches coils and proximity sensor when interlocked with a Poweramp leveler only
4. A Dim B l embedded mounting plate Part 7953 0119 then proceed with Bumper Projection Cantelever For filler requirements for 8 3 4 to 13 3 4 use cantilever bracket 9414 0055 and anchor cantilever bracket to the dock face 3 4 Dia X 5 1 4 min Kit 2103 0003 or RE weld to embedded mounting j un Plate Part 77953 0119 Dim B Driveway Mount Recommended when dock face is unsuitable for PowerHold Mounting Wedge Anchors Method Drive Embed Method Kit 2103 0003 Weld method Properly locate and level the drive embed weld Install six 6 3 4 Dia x 5 1 4 plate Part 7953 0132 in the drive approach Driveway mount requires attachment to min wedge anchors at the base Observe Cantilever conditions for proper a concrete drive greater than 8 thick of the PowerHold positioning Weld restraint to embed plate with a For asphalt drive pour 48 x48 x8 continuous 14 filet weld min concrete pad and include six 6 3 4 dowels into foundation wall Then proceed with adhesive anchors or weld plate embed f 14 Y 36 gt 48 A continuing product improvement process is in effect at Systems Inc We reserve the right to make product changes without prior notice Poweramp Division of Systems Inc e W194 N 11481 McCormick Dr e Germantown WI 53022 800 643 5424 fax 262 255 4199 www DockSys
5. For maximum protection use an OSHA approved locking device to lock out all power sources Only the person servicing the equipment should have the key to unlock the device Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the unit before maintenance is complete The maintenance prop must be in the upright service position when working under the dock leveler For maximum protection use an OSHA approved locking device to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the device ALWAYS disconnect electrical power source and ground wire before welding on dock leveler DO NOT ground welding equipment to any hydraulic or electrical components of the dock leveler Always ground to the dock leveler frame Failure to follow these instructions may result in damage to dock leveler and or serious personal injury or death DO NOT grind or weld if hydraulic fluid or other flammable liquid is present on the surface to be ground or welded DO NOT grind or weld if uncontained hydraulic fluid or other flammable liquid is present Stray sparks can ignite spills or leaks near the work area Always clean up the oil leaks and spills before proceeding with grinding or welding Always keep a fire extinguisher of the proper type nearby when grinding or welding Failure to follow these instructions may r
6. Relay or PLC contact is stuck contacts Test coil for Magnetism Coil must be de energized to release the truck Restraint does not raise Solenoid Not energized Locate solenoid See Page 42 but leveler raises Coil Must be energized when P Hold is in engage combination unit only mode Check valve for Magnetism at the coil Bad Spool Valve Remove coil from cartridge valve and cartridge valve from valve block Check valve for contaminant s and or damage Replace valve if damaged Carefully wipe valve with clean rag do not damage O rings on valve NOTE Do not over tighten valve into block Max Torque 10 15 Ib ft or snug to prevent leakage Tighten coil snug avoid over tightening and causing valve to bind Operate unit Replace valve if problem persists and all other troubleshooting procedures performed 4111 0016 January 2014 31 TROUBLE SHOOTING POWERHOLD Restraint will not lower to release truck Solenoid not energized Bad Spool Valve Restraint will not lower but leveler raises combination unit only Solenoid not Energized Bad Spool Valve 32 Locate solenoid Coil Must be energized when P Hold is in disengage mode Check valve for Magnetism at the coil Remove coil from cartridge valve and cartridge valve from valve block Check valve for contaminant s and or damage Replace valve if damaged Carefully wipe valve with clean rag do not damage O rings on val
7. a tethered remote two people are required to engage the maintenance prop one person to operate the unit the other person to engage the maintenance prop Failure to follow these instructions may result in serious personal injury or death NOTE Test operating range of PowerHold without transport vehicle backed into dock 1 Make sure the selector switch is in Normal and BYPASS mode has not been activated Red Inside Light No Amber Light Green Outside Light 2 Momentarily press the ENGAGE button The PowerHold restraint will raise to 90 deg NO transport vehicle the restraint will lower back to the stored position and shut off Inside Amber Light for 30 seconds then Red Alarm will sound if equipped Outside Red Light for 30 seconds then Green Operating range Refer to page 10 Follow the installation instructions found in the PowerHold Installation amp Operation Manual prior to attempting any adjustments 22 4111 0016 January 2014 ADJUSTMENTS PowerHold Adjustments P d Pd A J p d dd P d P di P ad Pod gt yet P Pag d d A Ne A xe Ps s A A di pS ze a pd P d d E Pa Ps pe pe d E A A P A P Pa P oe T d on a 4 P di a Pati Pid zd a d pd di i i Pad E P A a P E P p P pe gt m d a oe A UJ E 7 oS d a P d e x e 7 A P d P eo i E x P di x A xd gt 4 d A sut P di P di P P d A P Pd s P S p El lt aa ria P ad Paid lt Pd we Pd P d zT z radi z d A P
8. in serious personal injury or death Always stand clear of the dock leveler lip when working in front of the dock leveler The maintenance prop MUST be in the service position when working under the dock leveler For maximum protection use an OSHA approved locking device to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the maintenance prop Unless the dock leveler is equipped with a tethered remote two people are required to engage the maintenance prop one person to operate the unit the other person to engage the maintenance prop Failure to follow these instructions may result in serious personal injury or death 24 Dock leveler and vehicle restraint interlock options HE Interlock Dock leveler can be interlocked with a vehicle restraint to prevent the leveler from operating until the restraint has engaged the transport RIG Rear Impact Guard when the OPERATION switch is in NORMAL and has NOT been switched to BYPASS LS Interlock Vehicle restraint is interlocked with the dock leveler so that the restraint cannot be operated until the leveler is stored in the cross traffic position lip fully folded inside the keepers and the platform level with the dock floor Leveler and restraint interlocking are overridden when the OPERATION switch is in BYPASS This allows the independent operation of the leveler the restraint cannot be operated in
9. load amp value at any time including when operating in pressure relief The full load amp value can be found on the inside cover of the control panel Power Hold raises Slow or Pressure Relief cartridge adjusted per max amp Slow to release draw SC Power Hold Only Damage or blocked hydraulic Replace damaged hose s Check and remove hose s and or valve s blockage from hose s and or valve s 30 4111 0016 January 2014 TROUBLE SHOOTING POWERHOLD Low hydraulic fluid Add fluid see Maintenance section for proper fluid level and type Restraint does not fully raise or motor over current device and Debris in Tank Drain and clean tank debris cannot be cleaned out replace tank or overload device continuously tripping Restraint does not raise Bad Spool Valve Remove coil from cartridge valve and cartridge valve from valve block Check valve for contaminant s and or damage Replace valve if damaged Carefully wipe valve with clean rag do not damage O rings on valve NOTE Do not over tighten valve into block Max Torque 10 15 Ib ft or snug to prevent leakage Tighten coil snug avoid over tightening and causing valve to bind Operate unit Replace valve if problem persists and all other troubleshooting procedures performed Solenoid energized Locate solenoid See Page 40 amp 41 Coil should not be energized when P Hold is in engage mode models with stored prox only
10. maintenance prop Lock the The maintenance prop MUST be in the service maintenance prop in the service upright position position when working under the dock leveler using an OSHA approved lockout device C and tag For maximum protection use an OSHA approved out device B locking device to lock the maintenance prop in the service position Only the person servicing Whenever servicing the dock leveler lock the the equipment should have the key to unlock the electrical power disconnect in the OFF position Use maintenance prop only an OSHA approved lockout device C and tag out device B Unless the dock leveler is equipped with a tethered remote two people are required to engage the Only the person servicing the equipment should have maintenance prop one person to operate the unit the capability to remove the lockout devices The tag the other person to engage the maintenance prop out devices must inform that repairs are in process and clearly state who is responsible for the lockout Failure to follow these instructions may result in condition serious personal injury or death Refer to OSHA regulation 1910 146 Refer to OSHA regulation 1910 147 18 4111 0016 January 2014 MAINTENANCE Periodic Maintenance Apply Moly Alumaplex Ep grease or equivalent Daily Maintenance E Failure to properly lubricate the vehicle restraint Make sure that all the Inside and Outside signal will cause abnormal operation of the
11. or vehicle restraint Make sure proper service and maintenance procedures have been performed on 2 equipment before using Transport vehicles wheels must be chocked unless Arc Flash and the vehicle restraint is used Never remove the shock Hazard wheel chocks until loading unloading is finished PPE Personal Protection and transport vehicle has been given permission to Equipment Required leave De energize equipment before working on or inside Do not open cover without appropriate Make sure platform lip rests on the transport PPE Refer to NEPA JOE for vehicles bed with at least 4 in 102 mm of PPE requirements This panel overlap may contain more than one power source Maintain a safe distance from side edges of leveler Hazardous Voltage during the loading unloading process Will Cause Severe 9 g J P l Injury or Death Failure to follow these instructions may result in serious personal injury or death 14 4111 0016 January 2014 SEQUENCE OF OPERATION NORMAL 1 Check that the transport vehicle is positioned squarely against the dock bumpers Inside Red Light Outside Green Light 2 Push ENGAGE button to activate restraint Inside Green and Yellow Light Outside Red Light 3 ENGAGED on vehicle Restraint Inside Green Light Outside Red Light 4 Visually inspect restraint for proper engagement If RIG Rear Impact Guard is damaged or missing dock leveler can be used in BYPASS IF BYPASS MODE I
12. 7 310 311 312 313 314 315 316 317 318 319 320 322 323 4111 0016 January 2014 LADDER LOGIC POWERHOLD W LEVELER AAA AR E 11 2 I 115 V 1 PHASE 60 HZ I 100 V 240 VAC I 100 101 102 M1 ENERGIZES HYDRAULIC s I I SOL A DIRECTS FLUID TO RAISE RESTRANT WHEN DE ENERGIZED SOL B DIRECTS FLUID TO RAISE LEVELER WHEN DE ENERGIZED RAISE OR LOWER RESTRAINT WHEN ENERGIZED CR2 OPTIONAL DRY CONTROL CIRCUIT DE ENERGIZED WHEN T ENGAGED ON ICC BAR ENERGIZED WHEN ENGAGED ON ICC BAR DE ENERGIZED AT ALL TIMES WHILE IN BYPASS ALMI OPTIONAL ENERGIZED FOR 30 SECONDS IF RESTRAINT DID NOT AN ICC ALSO ENERGIZE IF RESTRAINT IS FULLY RAISED UPON P LT2 amp LT4 ENERGIZED ANYTIME RESTRAINT IS IN MOTION ENERGIZED FOR 30 SECONDS IF RESTRAINT DID NOT ENGAGE AN ICC BAR ENERGIZED AT ALL TIMES WHILE IN BYPASS LT6 DO NOT BACK IN OR PULL AWAY LTS OK TO BACK IN OR PULL AWAY SOL C OPTIONAL E STOP LEVELER ONLY BLOCKS FLUID FROM LEVELER TO RESERVOIR WHEN ENERGIZED l I l OPTIONAL l PBS ef als t y ow 3 SOL D OPTIONAL LIP OUT OR UP OUT STOP OR DIRE TO RAISE CTS FLUID UP WHEN ENERGIZED Generic Drawings are Shown Provide serial number for specific drawings 39 PROGRAMMING ISSUES FOR PROGRAMMING Error light is flashing PLC is either missing or damaged U
13. Always stand clear of the dock leveler lip when working in front of the dock leveler The maintenance prop MUST be in the service position when working under the dock leveler For maximum protection use an OSHA approved locking device to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the maintenance prop Unless the dock leveler is equipped with a tethered remote two people are required to engage the maintenance prop one person to operate the unit the other person to engage the maintenance prop Failure to follow these instructions may result in serious personal injury or death Raise platform fully and engage the maintenance prop in the service position Allow platform to rest on the prop so the lip will fully fold until it contacts the lip stops Turn OFF all electrical power to the dock leveler Attach safety lockout and tag out devices 4111 0016 January 2014 OPTIONAL EQUIPMENT ADJUSTMENTS IMPORTANT Anytime proximity switch and target are adjusted always check for interference between target and switch before operating the leveler Damage to switch will occur if the target contacts the switch The maximum torque for proximity switch lock nuts is 27 Nem 29 Ib ft Damage to switch will occur if maximum torque is exceeded A 1 4 in 6 4 mm Approximate B Target C 1 in 25 4 mm Approximate D Lock Nuts E Proxim
14. BYPASS Pressing the restraint ENGAGE button when in BYPASS mode will return the leveler to NORMAL operating mode This option is not available on units equipped with the Auto Return to Dock option 4111 0016 January 2014 OPTIONAL EQUIPMENT ADJUSTMENTS Adjust amp Test Dock Leveler and Vehicle Restraint Interlock Platform Full Lip Outside Below Dock Level Lip Keepers Target not in sensing range of switch IMPORTANT Work lip by hand when making Lip adjustments to make sure that target does NOT contact switch as lip extends The dock leveler should be in the cross traffic position before beginning tests Back a transport vehicle with RIG bar into dock A test fixture may be used to simulate the RIG bar Use care to avoid damage to the equipment or harm to the operator Press the RAISE push button The dock leveler should NOT raise If the leveler did not raise proceed with step 4 If the leveler did raise decrease dimension A or B so that the target is in the sensing range of the switch Typical factory settings for A and B are approximately 3 4 and 1 8 respectively Make adjustments at switch dimension B and or target dimension A until leveler does not raise when the vehicle restraint is not engaged on transport vehicle HIG bar Momentarily press the ENGAGE button The vehicle restraint automatic engage cycle will be activated and the restraint will engage the transpo
15. IONS Coordinate powerpack location and hose 2 Conduit From The Control Box length for proper placement Control Box Door Opening 3 4 Electrical Conduit From The Control Box To The Electrical Pit Junction Box By Others Dock Face Self Contained Appropriate location when the likelihood of flooding snow removal and damage from trailer trucks is minimal Also recommended for use with non hydraulically powered dock levelers Outside Signal Allow 8 Enough l rm Clearance 3 PVC Chase for Optional Ra Powerpack Locations f Seal or Shelter Under The Dock Leveler Bumper When combined with hydraulic leveler pump or remotely mounting under leveler make certain to locate the powerpack where leveler will not interfere in below dock conditions The routing of hydraulic and electrical lines from the powerpack to the restraint are best placed through min 3 PVC hydraulic and 3 4 Embed Plate Located 2 4 X4 Elec Junction 3 PVC Pipe For Above Grade Box At The Pit i i Hydraulic Hoses And Powerhold Puls E electrical By Others chase during pit construction PowerHold Imbed Plate 3 8 x 20 x 20 POWERHOLD REMOTE MOUNT POWERPACK CONTROL BOX VW CONDUIT FROM THE CONTROL BOX NEMA 12 TO OUTSIDE SIGNAL LIGHT ASSEMBLY Inside Building Remote Mount Locate powerpack to minimize Up obstruction potential Hydraulic and IA electrical lines from t
16. Number Description A 1 Hydraulic Valve Body B 1 9571 0007 Fitting Pipe Plug 1 8 NPT C 2 9301 0109 Fitting Conn STR Thread D 2 8581 0113 Fitting Elbow 90 Deg 6 ORB x 6 JIC E 1 8581 0089 Valve Cartridge Relief F 1 8581 0149 Valve Cartridge 4 Way D 1 8583 0018 Complete Valve Assembly H 1 8581 0004 Coil Delta 1 4305 0319 Cable Assembly 22 Lg 4111 0016 January 2014 43 PARTS PowerHold Break Down Provide dock leveler and or PowerHold serial number when calling or faxing orders 44 4111 0016 Januar y 2014 PowerHold Break Down PARTS Item Quantity Part Number Description A 1 9414 0064 Hestraint Shoe B 1 9412 0030 Pin 1 1 2X 8 LG C 1 9414 0021 Hack Weldment D 1 9411 0005 Spring Rack Weldment E 1 8583 0018 Valve Block F 1 9414 0018 Latch Block Assembly Includes Prox Switches G 1 2101 0118 Bolt 3 4 10 UNC X 1 1 2 LG H 1 2101 0119 Bushing 1 9414 0073 Cylinder Complete Includes Slide Block and Hoses J 1 9904 0059 Hose 35 Lg 6 Jic Swivel Both Ends K 1 9904 0155 Hose 21 Lg 6 Jic Swivel Both Ends L 1 9412 0095 Push Rod M 1 2101 0045 Cotter Pin 1 8 x 1 00 N 2 9412 0063 Removable Track Stop O 4 2101 0009 Bolt 5 16 18 P 1 9411 0056 Access Cover Top O 14 2101 0099 Screw 1 4 20 UNC x 3 8 R 1 9411 0060 Cover Front S 1 9411 0058 Weather Seal Hold Down T 1 0192 0016 Weather Seal Ratchet T i 2753 0001 J Box Cove
17. ONTACT RATING A600 CR2 CONTACT RATING 7 5 A GEN USE 120 VAC POWERAMP PROVIDES YELLOW COLOR 14 16 AWG CONDUCTORS FOR THIS WIRING 112 7 olo C 2n 1 2 14 13 I DE ENERGIZED WHEN 113 Generic Drawings are Shown Provide serial number for specific drawings 4111 0016 January 2014 37 LADDER LOGIC POWERHOLD W LEVELER 1 Prox Switch See Page 23 2 Prox Switch See Page 23 38 210 211 212 213 216 217 218 219 SS DC OUT PBI ACTIVATES RESTRAINT PB2 ACTIVATES RESTRAINT KS OPEN IN NORMAL CLOSED IN BYPASS PRSI INDICATES RESTRANT NOT FULLY RAISED WHEN OPEN FULLY RAISED WHEN CLOSED PRS2 INDICATES RESTRAINT NOT ENGAGED ON ICC BAR WHEN OPEN ENGAGED ON ICC BAR WHEN DOOR OPEN CONTACT IF U INDICATES DOOR NOT FULLY RAISED WHEN OPEN FULLY RAISED WHEN CLOSED PRS3 OPTIONAL LS INTERLOCKING INDICATES LEVELER LIP FULLY FOLDED WHEN CLOSED NOT FULLY FOLDED WHEN OPEN SEE NOTE M OPTIONAL DOOR CLOSED CONTACT INDICATES DOOR FULLY LOWERED WHEN CLOSED NOT FULLY LOWERED WHEN OPEN SPARE INPUTS PR4 INDICATES RESTRAINT FULLY LOWERED WHEN CLOSED pill d LOWERED WHEN PRS3 OPTIONAL AUTO RETURN INDICATES LEVELER LIP NOT AT FULL BELOW DOCK POSITION WHEN OPEN AT FULL BELOW DOCK POSITION WHEN CLOSED 4111 0016 January 2014 sa 30
18. Operation 1ccceeeeeeeeee einen rese nennen nana nanus 15 PowerHook Light Sequence eee ee eeee reser 16 Place art m 17 Maintenance Service Dock Leveler Restraint Safely 18 Periodic Maintenance eee Leere ree eene enne nnn nnn 20 Adjustment And Testing Testing PowerHook Operating Range 22 Adjust Dock Leveler and Vehicle Restraint Interlock 24 Adjust Auto Return To Dock ARTD 26 Troubleshooting TFOUUbIESNOOLI o entm 29 PLG Troubleshooting e 36 Electrical DIWO TET E 37 A PPP 40 Manual Relea Se Me 41 Parts VAWE BIOCKS A 42 PowerHold Break Down occooccooccconcconcconaconanconononanenancnnnrnnnrnnarenanenannes 44 Power Pack Assembly Self Contained 46 Lateh ASSem DIV ET m T 47 Power Pack Assembly Remote Mount 48 DUNES TCS SIGNS t 50 Outside ONIS O X v X 51 Miscellaneous Customer Information cccccseeeseseeeceeseecenseeseenseseenseseenseseeeneesones 53 Ac APA Back Cover 4111 0016 January 2014 Recognize Safety Information Safety Alert Symbol The Safety Ale
19. PowerHold a M Ch Pu 4 a E E ti y A j j y j i r BP MEM BEN i y j EN 4 d f f A y x 7 a i 1 4 4 a Ti ia e E K A Division of Systems Inc POWERHOLD amp POWERHOLD SC POWERAMP Division of Systems Inc W194 N11481 McCormick Drive Germantown WI 53022 Manual No 4111 0016 January 2014 800 643 5424 fax 262 255 5917 www docksystemsinc com techservices docksystemsinc com Printed in U S A Copyright 2014 Table of Contents Page Safety Recognize Safety Information eese 1 General Operational Safety Precautions 1 Operational Safety Precautions e e eeeeee eese 2 Maintenance Safety Precautions ee essere 4 lade m 5 Owner s User s Responsibilities 7 Introduction General Information 11 e ceeee eee Leee ceres ere ie eene nnne naa nnns 8 Hie E T A ue 9 Installation PowerHold Installation Overview 10 Component Identification 1 eee eeeee eese eee 12 Operation Operating Instructions a iuco ooi uecueu inui Dese iaa anio aecsa adu Cede RKREMeUES 14 Sequence of
20. PowerHold and Leveler Coil De energized to raise Leveler Energized to raise or lower the restraint Al JESCRIP TION PRESSURE FROM PUMP RETURN 10 PUMP Picos U EU BOE qp ELURN FROM LOGIC BLOCK MEE PRESSURE 10 POWERHOLO OJO RETURN FROM POWERHOLD Item Quantity Part Number Description A 1 8581 0011 4 Way Cartridge Valve B 2 9301 0113 Fitting Elbow 90 Deg STR Thread 6 ORB x 6 JIC C 1 9301 0115 Fitting Elbow 90 Deg STR Thread 6 ORB x 8 JIC 1 8581 0016 Fitting Elbow 90 Deg STR Thread 8 ORB x 8 JIC F 1 8583 0015 Complete Valve assembly G 1 8581 0004 Coil Delta H 1 4301 0001 Cable Assembly 48 Lg Provide dock leveler and or PowerHold serial number when calling or faxing orders 42 4111 0016 January 2014 PowerHold Valve Block Coil De energized to raise restraint Energized to lower the restraint PARTS U GS O JESCRIPTION PRESSURE FROM PUMP RETURN TQ TANK 10 BLIND END OF POWERHOLO CYLINDER TO ROD END OF POWERHOLD CYLINDER Item Quantity Part
21. Proximity Switch F Lip Hinge Tube C Bracket G Platform Lip D Lock Nuts H Indicator Light Standard PH levelers are equipped with the Auto Heturn To Dock ARTD unless leveler is interlocked with a vehicle restraint The ARTD allows the platform to automatically return to the cross traffic stored position after the transport vehicle departs The ARTD uses a proximity switch B located under the platform and a piece of angled steel called the target E that is attached to the lip hinge tube F The proximity switch provides a six second delay after the platform has lowered to the full below dock position after which the platform will return to the cross traffic position The switch also contains an indicator light H that can be used for diagnosing and adjusting the switch NOTE Some proximity switches have an indicator light at the back of the housing and some have the light at the side of the housing 26 Adjust the ARTD as Follows 1 When service under the dock leveler is required always lock all electrical disconnects in the OFF position after raising the platform and engaging the maintenance prop Failure to do this may result in serious personal injury or death Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete Failure to do this may result in serious personal injury or death
22. S REQUIRED SEE SEQUENCE OF OPERATION BYPASS FOR NORMAL OPERATION AFTER TRAILER RIG IS ENGAGED CONTINUE WITH STEP 5 5 Position dock leveler onto transport vehicle 6 When loading or unloading is complete return dock leveler to the stored position 7 Release vehicle restraint and or remove chocks from transport vehicle wheel 4111 0016 January 2014 OPERATION SEQUENCE OF OPERATION BYPASS 1 Check that the transport vehicle is positioned squarely against the dock bumpers 2 Push ENGAGE button to activate restraint Inside Green Light Red Outside Light 3 Visually inspect restraint for proper engagement If RIG Rear Impact Guard is damaged or missing dock leveler can be used in BYPASS 4 f RIG Rear Impact Guard is damaged or missing Shoe will automatically return to the stored position Inside Amber Light and LED will flash for 30 seconds then Flash Red Do Not Enter Outside Red Light will flash for 30 seconds then flash Green 5 Secure transport vehicle wheels with wheel chock 6 Use key to activate BYPASS mode Inside Green Light with Amber Caution Light Outside Red Light 7 Position dock leveler onto transport vehicle trailer 8 When loading or unloading is complete return dock leveler to the stored position Inside Green Light with Amber Caution Light Outside Red Light 9 Reset BYPASS mode to NORMAL mode by pressing the ENGAGE button once Inside Red Light Ambe
23. acement of placard is near control box attached to electrical conduit by using nylon tie If there is no control box present mount placard on wall to the immediate left of leveler at eye level q FI qM SSN Y ferira OS ico AER iR o gt a Sty SS d Conduit bo 7 7 7 WAAAY AA AMA 4111 0016 January 2014 17 MAINTENANCE Service Dock Leveler Safely ORI ESSE SEN S I GBA p TAI I LL EI PCIA AAA DIAM LE A Maintenance Prop B Tag Out Device C Lock Out Device D Front Header When service under the dock leveler is required always lock all electrical disconnects in the OFF position after raising the platform and engaging the maintenance prop Failure to do this may result in serious personal injury or death Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete Failure to do this may result in serious personal injury or death Whenever maintenance is to be performed under the dock leveler platform support the platform with maintenance prop A Position the maintenance Always stand clear of the dock leveler lip when prop behind front header plate D while staying clear working in front of the dock leveler of the lip The lip will fold down after the platform has rested on the
24. ation Quarterly Maintenance IMPORTANT Failure to properly lubricate the dock leveler will cause abnormal operation of the leveler Lubricate the following areas with light weight machine oil A Lip hinge area unless equipped with grease fittings apply oil to the top of the entire length of lip hinge when platform is at the full below dock position and lip is folded D Dual lanyard lever pivot E Platform hinge area apply oil to top of all platform hinges when platform is at the full below dock position G Toe guard hinges along full length of top and bottom hinges H Platform cylinder to platform frame pin J Lip cylinder to platform frame pin K Lip lifter and lift cylinder pin Lubricate the following areas with white lithium grease B Valve lever pivot and top of logic block spool valve F All platform cylinder trunnions L Toe guard pivots where toe guard strut contacts pivot NOTE Apply grease to lip hinge grease fittings if equipped 4111 0016 January 2014 MAINTENANCE M Reservoir P Breather Cap N 2 in 51 mm From Top of Q Fluid Level Reservoir IMPORTANT A low fluid level or the use of hydraulic fluids not equivalent to the fluid types recommended will cause abnormal operation of the leveler and WILL void warranty e Check reservoir fluid level Q 1 Put the dock leveler platform at the full
25. below dock position 2 Turn OFF all electrical power to the leveler 3 Remove inspection plate C 4 Remove breather cap P 5 Measure fluid level The fluid level should be approximately 2 in 51 mm N from top of reservoir M with platform at the below dock position 6 Add hydraulic fluid if necessary Use only recommended fluid 7 Install breather cap and inspection plate 8 Turn ON electrical power to the leveler 9 Return the platform to the cross traffic position 21 ADJUSTMENT AND TESTING PowerHold Operating Range When service under the dock leveler is required always lock all electrical disconnects in the OFF position after raising the platform and engaging the maintenance prop Failure to do this may result in serious personal injury or death Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete Failure to do this may result in serious personal injury or death Always stand clear of the dock leveler lip when working in front of the dock leveler The maintenance prop MUST be in the service position when working under the dock leveler For maximum protection use an OSHA approved locking device to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the maintenance prop Unless the dock leveler is equipped with
26. cal B is located on the right side near The J Box When you receive your new equipment write down the model and serial number in the form provided This will help ensure safe keeping of the numbers in the event the model serial number decal A becomes lost or damaged Also write down Systems Inc s job number the company that installed the dock leveler and the original owner s name This will all help to identify the specific dock leveler if more information is required When ordering use part numbers and description to help identify the item ordered Do not use item numbers These are only for locating the position of the parts Always give dock leveler MODEL NUMBER and or SEHIAL NUMBER For service call or contact Systems Inc P O Box 309 Germantown WI 53022 Phone 800 643 5424 Fax 262 255 5917 4111 0016 January 2014 Dock Leveler Information Serial No Systems Inc Job No Vehical Restraint Information Serial No Systems Inc Job No Original Owner Information Date of Installation o3 STANDARD PRODUCT WARRANTY SYSTEMS INC warrants that its products will be free from defects in design materials and workmanship for a period of one 1 year from the date of shipment All claims for breach of this warranty must be made within 30 days after the defect is or can with reasonable care be detected In no event shall any claim be made more than 30 days after this warranty has expired In or
27. ck in service Any modifications or alterations of loading dock equipment shall only be done with prior written approval from the manufacturer and the same shall be at least as safe as the original equipment was prior to the modification and shall also satisfy all safety requirements of the manufacturer for the particular application of the leveling device When industrial moving devices are being used in the loading or unloading of product from the transportation vehicle this vehicle shall have the brakes and wheel chocks applied appropriately or all other positive restraining device shall be fully utilized It is recommended that trailers with air ride suspension systems shall have its air exhausted prior to performing loading and unloading operation to minimize trailer bed drop Loading dock safety equipment should never be used outside of its intended use vertical working range or capacity Please consult the manufacturer if you have any questions as to the use vertical working range or capacity of the equipment Only properly trained and authorized personnel should operate the equipment When selecting loading dock safety equipment it is important to consider not only present requirements but also future plans and any possible adverse conditions environmental factors or usage 4111 0016 January 2014 7 INTRODUCTION Congratulations on your choice of a Poweramp PowerHold vehicle restraint This manual covers the PowerHold vehicl
28. could cause a person to trip or fall SAFETY Operational Safety Precautions f Learn the safe way to operate this equipment Read and understand the A manufacturer s instructions If you have any questions ask your supervisor wor Stay clear of dock leveling device when transport vehicle is entering or leaving area Do not move or use the dock leveling device if anyone is under or in front of it Keep hands and feet clear of pinch points Avoid putting any part of your body near moving parts ks Chock restrain all transport vehicles Never remove the wheel chocks until loading or unloading is finished and driver has been given permission to drive away INT Tee Do not use a broken or damage dock leveling device Make sure proper service and maintenance procedures have been performed before using A e _ or Make sure lip overlaps onto the transport vehicle at least 4 in 102 mm Keep a safe distance from both side edges 4111 0016 January 2014 SAFETY E wer Do not use dock leveling device if transport vehicle carrier is too high or too low Do not overload the dock leveling device Do not operate any equipment while under the influence of alcohol or drugs Do not leave equipment or material unattended on dock leveling device 4111 0016 January 2014 3 SAFETY Maintenance Safety Precautions Hydraulic and electrical power must be OFF when servicing the equipment
29. der to be entitled to the benefits of this warranty the product must have been properly installed maintained and operated in accordance with all manufacturers recommendations and or specified design parameters and not otherwise have been subject to abuse misuse misapplication acts of nature overloading unauthorized repair or modification application in a corrosive environment or lack of maintenance Periodic lubrication adjustment and inspection in accordance with all manufacturers recommendations are the sole responsibility of the Owner User In the event of a defect as determined by SYSTEMS INC covered by this warranty SYSTEMS INC shall remedy such defect by repairing or replacing any defective equipment or parts bearing the cost for the parts labor and transportation This shall be exclusive remedy for all claims whether based on contract negligence or strict liability WARRANTY LIMITATIONS THE ABOVE WARRANTIES ARE IN LIEU OF ANY OTHER WARRANTIES WHETHER EXPRESSED OR IMPLIED INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SYSTEMS INC AND ITS SUBSIDARIES SHALL NOT IN ANY EVENT BE LIABLE TO ANYONE INCLUDING THIRD PARTIES FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY KIND INCLUDING BUT NOT LIMITED TO BREACH OF WARRANTY LOSS OF USE LOSS OF PROFIT INTERUPTION OF BUSINESS OR LOSS OF GOODWILL PRODUCT SPECIFIC WARRANTY PowerHolde SERIES VEHICLE RESTRAINT
30. e control panel Proximity switch indicator light is OFF If the platform lip is resting on the truck bed the platform will stay at this position unless the operator activates the leveler 4111 0016 January 2014 TROUBLESHOOTING POWERHOLD When service under the dock leveler is required Always stand clear of the dock leveler lip when always lock all electrical disconnects in the OFF working in front of the dock leveler position after raising the platform and engaging the maintenance prop Failure to do this may result in The maintenance prop MUST be in the service serious personal injury or death position when working under the dock leveler For maximum protection use an OSHA approved locking device to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the Always post safety warnings and barricade the maintenance prop work area at dock level and ground level to prevent unauthorized use of the dock leveler before Unless the dock leveler is equipped with a tethered maintenance is complete Failure to do this may remote two people are required to engage the result in serious personal injury or death maintenance prop one person to operate the unit the other person to engage the maintenance prop Failure to follow these instructions may result in serious personal injury or death Before performing the detailed troubleshooting procedures check the following
31. e restraint operating system Designed by Poweramp to be a marvel of simplicity and efficiency your vehicle restraint when properly installed will provide many years of trouble free performance with an absolute minimum of maintenance Its revolutionary hydraulic system efficiently controls and operates every function To obtain maximum performance and longest possible use a simple program of preventive maintenance is recommended and is outlined in this manual The PowerHold vehicle restraint is designed to seek find and maintain a tight continuous hold on the HIG Rear Impact Guard bar effectively eliminating trailer creep As an optional safety feature the dock leveler and vehicle restraint can be interlocked preventing operation of the dock leveler until the hold engages the ICC RIG bar The vehicle restraint is firmly anchored to the drive way approach or the building wall for maximum holding power The PowerHold restraint is designed to withstand a pulling force of 30 000 Ibs The PowerHold vehicle restraint comes equipped with an electrical control panel which allows push button operation of the vehicle restraint functions When combining a Poweramp Dock Leveler with a PowerHold vehicle restraint the control panel will allow for operation of both units in the same control panel Each PowerHold Poweramp Dock Leveler and control panel has been factory prewired and tested to ensure Satisfactory operation To i
32. efore allowing vehicle to leave the dock always e Ensure no equipment material or people are on dock leveler e Return dock leveler to its stored position at dock level cards waring labek sides 1751 0329 x2 decal placed in same position on both sides 1751 0330 x2 decal placed in same position on both sides A DANGER CRUSH HAZARD 1 7 5 1 0 1 3 8 DO NOT REMOVE hydraulic cylinder until leveler is safely supported by maintenance prop Refer to owner s user s manual for proper maintenance procedure Failure to comply will result in death or serious injury 1751 0729 CRUSH HAZARD Do not work under dock leveler unless this maintenance prop has been secured in the upright position Failure to comply will result in death or serious injury See owner s user s manual for proper procedures 1751 0729 Rev A AM DANGER A DANGER CRUSH HAZARD Rotate prop to maintenance position Open the pin latch 1 751 0731 and insert through the maintenance prop housing Close the pin latch to secure prop Use every time dock leveler is serviced Failure to comply will result in death or serious injury 1751 0731 RevA A DANGER CRUSH HAZARD DO NOT ENTER PIT unless dock leveler is 75 7 securely supported by maintenance prop Place barriers on driveway and dock floor to indicate service work being performed Failure to comply will result in death or serious injury Refer to owner s use
33. er Loading Dock Equipment Www DockSystemsInc com 1751 0880 OPERATING INSTRUCTIONS VEHICLE RESTRAINTS ENGAGE RESTRAINT 1 Open overhead door and visually check that truck is positioned squarely against dock bumpers and has a RIG bar Inside light is RED and outside light is GREEN 2 Depress the ENGAGE button to activate restraint 3 Once RIG has been secured inside light is GREEN outside light is RED RELEASE RESTRAINT 1 To release truck restraint depress the RELEASE button When safely stored inside lightis RED and outside lightis GREEN BY PASS 1 If restraint is unable to secure transport vehicle s RIG use wheel chocks to secure transport vehicle atthe dock 2 Turn switch to BY PASS Inside light is GREEN outside light is RED 3 Loading unloading may proceed with caution BY PASS RESET RETURN TO NORMAL OPERATION 1 When loading or unloading is completed and wheel chocks are removed manual reset of BY PASS is accomplished by depressing the RELEASE button or turning switch to NORMAL Lights change to RED inside GREEN outside ET 1751 0880 Placard Vehicle Restraints Vehicle Restraints 52 4111 0016 January 2014 Customer Information MISCELLANEOUS NOTE Refer to illustration for left right orientation of dock leveler The LEVELER model serial number decal A is located on the right platform joist near the front lip of dock leveler The RESTRAINT model Serial number de
34. esult in serious personal injury or death ALWAYS stand clear of dock leveler lip when working in front of the dock leveler Failure to do this may result in serious personal injury or death 44 DANGER A Y Arc Flash and Shock Hazard PPE Personal Protection Equipment Required De energize equipment before working on or inside Do not open cover without appropriate PPE Refer to NFPA 70E for PPE requirements This panel may contain more than one power source Hazardous Voltage Will Cause Severe Injury or Death 4111 0016 January 2014 SAFETY Dock Leveler Safety Decals Every 90 days quarterly inspect all safety labels and tags to ensure they are on the dock leveler and are easily legible If any are missing or require replacement please call 1 800 643 5424 A DANGER CRUSH HAZARD Maintenance prop must fo r re p ace m e nts support leveler behind bar 1 751 0727 Do not force maintenance prop forward of bar to support lip Failure to comply will result in death or serious injury Refer to owner s user s manual for proper use 1751 0730 x2 AA DANGER Unsupported dock leveler ramps can lower unexpectedl BSS 7 amm 1751 0330 x2 decal placed in same position on both sides AADANGER CRUSH HAZARD Do not remove main springs until leveler is securely supported by a suitable lifting device Main sprin
35. g or faxing orders 4111 0016 January 2014 49 PARTS Outside Signs Item Quantity Part Number Description SIGN PULL IN OUT ON GREEN ONLY A 1 1751 0033 RIGHT READING 16 7 8 x 8 x 3 32 SIGN PULL IN OUT ON GREEN ONLY 1 1751 0034 MIRROR IMAGE 16 7 8 x 8 x 3 3 50 4111 0016 January 2014 PARTS OSLA Outside Light Assembly item Quantity Part Number Description Complete Light Housing Yellow Plastic LED Lights Complete Light Housing Yellow Plastic Incandescent Lights Light Housing Only Yellow Plastic Lens Red for use with incandescent bulbs Lens Green for use with incandescent bulbs Lamp 25W 120V Incandescent BAY Rated 1000 Hours oocket Harness for Incandescent Lamp Lens Housing Circuit Assembly Red LED Lens Housing Circuit Assembly Green LED Mounting Gasket Clips Lens Holding 6 4 3051 0104 Screw Lens Holding Clip Conduit Fastener 3 4 x 3 8 Included in Complete assembly Not shown in diagram 4111 0016 January 2014 51 PARTS DANGER e Read and follow all instructions warnings and maintenance schedules in the manual and on placards e Vehicle restraint operation and servicing is restricted to trained personnel 1 Before using the vehicle restraint e Remove any debris snow or ice that may obstruct vehicle restraint operation Alert personnel in the area of potential vehicle restraint operation and ensure a
36. gs contain stored energy Be sure springs are fully unloaded and ends are loose before removal Failure to comply will result in death or serious injury Refer to owner s user s manual for proper maintenance procedure 1751 0728 R AA DANGER dock leveler unless this maintenance prop has been secured in th ill result in death or serious injury See owner s user s manual for prop 1751 0 A DANGER CRUSH HAZARD Open the pin latch and insert through the maintenance 1 7 5 1 0 7 8 g prop housing and prop completely Close the pin latch to secure prop Use every time dock leveler is serviced Failure to comply will result in death or serious injury 1751 0726 owner s user s manual for proper maintenance procedures Note This 1s a example of dock leveler safety decals See manual for your specific model for correct safety decal sheet or consulate Tech Serves 4111 0016 January 2014 5 SAFETY DECALS Every 90 days quarterly inspect all safety labels and tags to ensure they are on the dock leveler and are easily legible If any are missing or require replacement please call 1 800 643 5424 A DANGER CRUSH HAZARD for replacements 1 751 0727 support leveler behind bar Do not force maintenance prop forward of bar to support lip Failure to comply will result in death or serious injury Refer to owner s user s manual for proper use 1751 0727 Rev A 1751 0730 x2 SAFETY INFORMATION B
37. he powerpack E f V7 3 PUMP PANEL ANCHORED to the restraint are best placed N 7 POWER 1PH OR 3PH TO WALL 4 PLACES through min 3 PVC hydraulic Pu A and 3 4 electrical chase during pit umm OUTSIDE SIGNAL construction HT 7 LIGHT ASSEMBLY IW SANS SS OS IAS PEN NR AN POWERPAC RETURN LINE FROM PIT PRESSURE LINE TO PIT 24 VDC CONTROL CIRCUIT 115 VAC teoria TO POWERHOLD L BUMPERS IO PH PR 12 13 SNL 10 4111 0016 January 2014 INSTALLATION A Division of Systems Inc POWE MP PowerHold Installation Overview i TITU I For comprehensive installation instructions read and understand the Premium Loading Dock Installation and Operation Manual Concrete Dock Face Standard installation Wedge Anchors Method Weld Plate Embed Method Using back plate as a guide drill six 6 holes Weld three sides of PowerHold back plate to the for wedge anchors 3 4 x 5 1 4 min Kit optional embed mounting plate Part 77953 0119 2103 0003 with continuous 1 4 fillet weld gt 51 4 minimum m 20 __ 20 I I Embed p A Plate located 2 Ly i Eo above grade DD 3 8 ret PRO Wall Mount subtract 4 Dim Determine offset pa For filler requirements from 1 Y2 to 7 V2 use cantilever bracket 9414 Driveway Mount 0054 and anchor cantilever bracket I I instructions below to the dock face or weld to Dim
38. ires Bad prox switch Activation of 1 prox switch Input 4 must come on first The restraint shoe must make contact with the ICC bar The restraint shoe will rotate as the hydraulic extends The Slide block on the hydraulic cylinder push The rod The rod will make contact with the Z bar The Z bar will pass over the 1 prox switch Input 3 will light on the PLC The power hold then shut off Frozen or rusted push rod Bend or damaged Z bar adjustment to prox maybe required Activation of 2 prox switch The restraint shoe must make contact with the ICC bar The restraint shoe will rotate the ratchet will pass in front of the 2 prox switch input 4 Platform does not rise Pump operates in pressure relief mode Heavy object s on platform Remove object s from platform NOTE For safety reasons the dock leveler is designed to lift only the platform s own weight Dock leveler binds Check for visible obstructions that could cause binding Remove obstructions If no obstructions found call Poweramp Technical Services See inside back cover for phone number and address Pressure relief set too low Increase pressure relief See Adjust Main Pressure Helief in the Adjustment section NOTE The pressure relief valve must not be set at a level that causes the motor operating current to exceed the full load amp value at any time including when operating in pressure relief The full load amp value can be found
39. items first e Check all fuses inside the control panel s Replace e Make sure the correct voltages are present at the any blown fuse s with a fuse of equal specification proper locations inside the control panel s Inside and outside signal Bad Flasher Replace flasher with wire If lights operate lights lights do not operate will not flash replace flasher Controller PLC RUN indicator is on solid not flashing Unit operates as normal Restraint does not Motor overload device Heset overload relay 3 phase or replace fuse 1 operate Motor does not tripped phase or reset breaker 1 phase new models energize Determine cause of device tripping NOTE f replacing fuse use fuse with equal specification Motor starter 3 phase or Check controller output that sends a signal to starter motor relay 1 phase not or relay Output may have failed OPEN Use meter energizing Combination to check for contact closure when output ON Leveler and P Hold Only 4111 0016 January 2014 29 TROUBLE SHOOTING POWERHOLD Three phase units only 3 Phase units only no Check for blown fuses at branch circuit disconnect Restraint does not voltage is present on one Replace fuse Determine cause of blown fuse operate Motor energizes line Check motor starter as follows AO OO a ORTAN 1 Disconnect wires at load side of starter 2 Energize the starter 3 Measure line to line voltage at line side of starter 4 Meas
40. ith the ARTD operation Use the following illustrations to assist in fine tuning and or diagnosing the ARTD operation Cross Traffic Position Lip Keeper NOTE The platform lip is fully folded when the platform is at the cross traffic stored position lip engaged with keepers or when platform is resting on the maintenance prop Whenever the platform lip is at the cross traffic position the following conditions will exist for a normally operating ARTD Target not in the sensing area of proximity switch Proximity switch OFF open no signal sent to control panel Proximity switch indicator light is OFF Platform stays at this position unless the operator activates the leveler 27 OPTIONAL EQUIPMENT ADJUSTMENTS Full Below Dock Position Lip Keeper Whenever the platform lip is at the full below dock position the following conditions will exist for a normally operating ARTD Proximity switch senses target Proximity switch ON closed signal sent to the control panel Proximity switch indicator light is ON Platform will automatically rise after approximately a six second delay then returns to the cross traffic position 28 Lip Fully Extended Position Whenever the platform lip is at the fully extended position the following conditions will exist for a normally operating ARTD Target not in the sensing area of proximity switch Proximity switch OFF open no signal sent to th
41. ity Switch NOTE Distances A and C are typical factory settings Use these dimensions only as a starting point when adjusting the proximity switch and target especially if switch and or target have been replaced When dimensions A and C are obtained the proximity switch and target may need finer adjustments to get the ARTD to operate satisfactorily 3 Loosen lock nuts D Adjust proximity switch E to obtain distance A Tighten lock nuts 4 Bend target B as needed to obtain distance C Recheck distance A and readjust if necessary NOTE At least two people may be required to manually move the lip After adjusting proximity switch and target slowly move the lip up by hand while observing the target and proximity switch The target MUST NOT contact the switch otherwise damage to switch will occur Readjust switch and or target if necessary then recheck for interference 4111 0016 January 2014 Turn ON electrical power to the dock leveler Disengage the maintenance prop Turn the ARTD switch on control panel to the ON position Raise the platform until the lip is fully extended then allow the platform to drift to the below dock position After approximately 6 seconds the platform must return to the cross traffic position 10 Adjust the proximity switch and target as necessary Make small adjustments then operate the dock leveler to check results Do this until satisfied w
42. llustrate which connections are to be made in the field at installation electrical drawings are included with each order or by contacting Poweramp Technical Services Once again thank you and congratulations on your purchase of a Poweramp PowerHold vehicle restraint Due to ongoing product improvement some parts have changed along with operation and trouble shooting methods For further assistance please contact Poweramp Technical Service at 800 643 5424 or techservices docksystemsinc com 4111 0016 January 2014 OPERATION When the Engage button A is pushed on the control panel this activates an electric motor which drives a hydraulic pump The hydraulic pump forces oil into the hydraulic cylinder causes the shoe to rotate upward The shoe will make contact with the ICC bar The pump will shut off once the shoe is at 90deg Once the vehicle is locked the leveler Raise button will be activated D When the Release button B is pushed the motor will run and lower the shoe After the shoe is stored the pump will turn off only on units with stored switch If no ICC Bar is preset PowerHold can be operated in Bypass C 4111 0016 January 2014 9 A Division of Systems Inc INSTALLATION MP PowerHold Installation Overview I OWE For comprehensive installation instructions of the PowerHold Premium Loading Dock AMI read and understand the Installation and Operation Manual POWERPACK LOCATION OPT
43. nt is not fully lowered Inside and out Possible damaged switch and or bad wire connections 4111 0016 January 2014 35 POWERHOLD PLC LIGHTS PLC LIGHTS INPUT OUTPUT STORED 7 8 13 8 9 IN MOTION 0 2 6 7 LOCKED 3 4 7 8 o 9 7 MISSED ICC 7 8 13 4 6 8 sec change too change 7 8 13 8 9 BYPASS 7 8 13 5 9357 HESET BYPASS PRESS THE RELEASE BUTTON TIMEOUT FAILURE 7 8 8 9 RED LIGHTS IN AND OUT LEVELER COMBINATION UNIT 5 MUST BE ON TO RAISE THE DOOR EMERGENCY STOP Where Equipped OVERRIDES EVERY OTHER CONDITION WHEN E STOP IS DEPRESSED INPUT 8 WILL BE OFF 36 4111 0016 January 2014 LADDER LOGIC POWERHOLD W LEVELER MAKE SURE CUSTOMER SUPPLIED 3 PHASE VOLTAGE MATCHES VOLTAGE ON CONTROL ASSY DECAL CUSTOMER SUPPLIED 208 230 460 575 VAC 3 PHASE 60 HZ DL FROM BRANCH CIRCUIT DISCONNECT SWITCH 100 amp OVERCURRENT DEVICE BY OTHERS 101 SELECT DISCONNECT SMTCH amp SEE TABLE 1 OVERCURRENT DEMCE PER THE NEC 102 LOCATE A DISCONNECT SWITCH 105 DUAL ELEMENT TIME DELAY HYD PUMP MOTOR FUSES MUST BE USED FOR BRANCH CIRCUIT PROTECTION 104 208 230 460 575 VAC 105 108 1 SEE TABLE 2 e o X1 45 120 vac X i 10 a cat m 4 ANP OPTIONAL OPTIONAL PB4 CRI E STOP E STOP 216 312 109 LU 13 CRI OPTIONAL E STOP E STOP ACTIVATED 110 111 OPTIONAL DRY CONTROL CIRCUIT FOR AIR SHELTER OR INFLATABLE SEAL OR OTHER CUSTOMER SPECIFIED EOVIPMENT SS2 C
44. on the inside cover of the A 4111 0016 January 2014 33 TROUBLE SHOOTING DOCK LEVELER Platform rises slowly Low hydraulic fluid Add fluid see Maintenance section for proper fluid level and type Contaminated hydraulic Clean and inspect valves Flush contaminated oil system from hydraulic system Fill system with new oil See Periodic Maintenance in the Maintenance section Damaged or restricted Heplace damaged hose s Remove restriction hydraulic hose s Pressure relief set too low Increase pressure relief See Adjust Main Pressure Helief in the Adjustment section NOTE The pressure relief valve must not be set at a level that causes the motor operating current to exceed the full load amp value at any time including when operating in pressure relief The full load amp value can be found on the inside cover of the control panel Pump motor loads down Pressure relief set too high Decrease pressure relief See Adjust Main Pressure when platform reaches Helief in the Adjustment section the full raised position NOTE The pressure relief valve must not be set at a level that causes the motor operating current to exceed the full load amp value at any time including when operating in pressure relief The full load amp value can be found on the inside cover of the control panel Shoe does not rise to full L ow hydraulic fluid Add fluid see Maintenance section for proper fluid height le
45. ormation as well as tables to identify the grade slope for all variations of length or configuration of the dock leveling device and information identifying the maximum uncontrolled drop encountered when sudden removal of support while in the working range of the equipment It is recommended that when the transportation vehicle is positioned correctly in the dock opening and in contact with both bumpers there shall be a minimum of 4 00 inches 100mm overlap of the leveling device and the transportation vehicle at all times during the loading and unloading process The Owner User must review all name plates placards decals instructions and posted warnings and place the same in view of the operator or maintenance personnel for whom such warnings are intended for Contact manufacturer for any replacements Manufacturers recommended periodic maintenance and inspection procedures in effect at the date of shipment shall be followed at all times Written documentation of maintenance replacement parts or damage should be retained In the event of damage notification to the manufacturer is required Loading dock equipment that has been structurally damaged or has experienced a sudden loss of main support while under load such as what might occur when a transport vehicle pulls out from under the leveling device shall be removed from service inspected by a manufacturers authorized representative and repaired or replaced as needed before being placed ba
46. pdate to newer program Installation of new un programmed PLC MATERIAL REQUIRED You will receive two 2 E proms Blank run E Prom Program Specific E Prom INSTALLATION 1 Turn power off power remove existing E Prom if present 2 Insert new Blank Run E Prom 3 Turn power on for 30 seconds Prom Location 4 Turn power off for 10 seconds repeat cycle 3 times Twido PLC Insert program chip program specific Repeat steps 1 3 and 4 Allow light sequence to complete flashing Run light should be on STEADY not flashing Error light should NOT be on Check for proper input and out put lights on the PLC If not repeat steps 3 and 4 until PLC responds properly If the PLC does not accept the program or if questions contact the Tech Service Department at 800 643 5424 Note The PLC will maintain the program even if the power is turned off E Prom 40 4111 0016 January 2014 MANUAL RELEASE Front Cover Slide Block Washer Bolt 3 4 Dia Rod Tools required Large Hammer 3 4 Dia Rod Two Foot Lg Manual release Lock out tag out leveler Remove front cover plate 4 screws Remove bolt and washer holding cylinder in place Install 3 4 rod through front opening Rod will fit in the slide block Hammer 3 4 rod 4 to 5 hits until the slide block travels past the shoe The shoe will then rotate down 4111 0016 January 2014 41 PARTS Valve Block Combination
47. r s manual for proper maintenance procedures Note This 1s a example of dock leveler safety decals See manual for your specific model for correct safety decal sheet or consulate Tech Serves 6 4111 0016 January 2014 10 OWNER S USER S RESPONSIBILITIES The owner user should recognize the inherent dangers of the interface between the loading dock and the transportation vehicle The owner user should therefore train and instruct all operators in the safe operation and use of the loading dock equipment in accordance with manufacturer s recommendations and industry standards Effective operator training should also focus on the owner s user s company policies and operating conditions Maintaining updating and re training all operators on safe working habits and operation of the equipment regardless of previous experience should be done on a regular basis and should include an understanding and familiarity with all functions of the equipment Owner s user s shall actively maintain update and retrain all operators on safe working habits and operations of the equipment The manufacturer shall provide to the initial purchaser all necessary information regarding Safety Information Operation Installation and Safety Precautions Recommended Initial and Periodic Inspections Procedures Planned Maintenance Schedule Product Specifications Troubleshooting Guide Parts Break Down Warranty Information and Manufacturers Contact Inf
48. r and Gasket SC includes screws 2753 0002 J Box Cover and Gasket Remote includes screws V 4 2101 0074 Screw Allen Head 1 2 20 UNC x 1 1 2 Lg W 1 9414 0074 Base Weldment X 1 8581 0137 One Way check Valve 4111 0016 January 2014 45 PARTS PowerHold SC Power Pac Pressure jo Return U A Y Ss B Item Quantity Part Number Description A 1 9301 0199 Breather Cap B 1 9411 0057 Cover Power Pac C 1 9301 0085 Filter 3 8 NPT D 2 9904 0051 Hose 16 00 LG 3 8 NPTM 46 Jic Swivel Female F 7 2101 0009 Bolt 5 16 18 UNC 3 4 Lg G 1 9395 0405 Power Pac Complete SC Includes Hoses Filter and Reservoir 6 8 FLA 46 4111 0016 January 2014 PARTS Po B Stored Prox Switch INPUT 13 Prox Switch INPUT 4 No Prox Switch S INPUT 3 Sq A Item Quantity Part Number Description 2 0961 0073 Prox Switch 0961 0563 Stored Prox Switch 0941 0008 Spring 0941 0009 Spring 2101 0012 Bolt 5 16 18 UNC 2101 0058 Nut Hex 5 16 18 UNC Qmmuoou 9414 0081 Latch Assembly Complete With Prox Switches 4111 0016 January 2014 47 PARTS Power Pack Assembly Remote Mount NOTE Helief valve will be set at max pres sure Systems pressure is set by relief valve on restraint 48 4111 0016 January 2014 PARTS Power Pack Assembly Remote Mount
49. r turns Off Outside Green Light Pressing the ENGAGE button during any part of the cycle will end the ENGAGE mode Pressing the LOCK button a second time will cycle the PowerHold 10 Un chock the transport vehicle wheel when transport vehicle is ready to depart OPERATION CONDITION STORED BEGIN END IN MOTION LOCKED BYPASS MISSED ICC TIMEOUT FAILURE TIMEOUT FAILURE IN MOTION PowerHold Light Sequence LIGHTS INSIDE O 9 RED O 6 AMBER O 5 GREEN O 5 O 6 GREEN AMBER O 6 22sec O 4 AMBER TIME RED O 9 O 6 RED AMBER O 8 AMBER OUTSIDE O 8 GREEN O 7 O 6 RED OPTIONAL STROBE 0 7 RED 0 7 0 6 RED OPTIONAL STROBE O 7 22sec 0 8 RED TIME GREEN OPTIONAL STROBE 0 8 O 7 O 6 RED OPTIONAL STROBE O 5 8sec O 8 RED OPTIONAL STROBE A NEW LOCK CYCLE OR BYPASS WILL OVERRIDE MISSED ICC TIMEOUT FAILURE OVERRIDE MISSED ICC EMERGENCY STOP Where Equipped OVERRIDES EVERY OTHER CONDITION O 4 WHEN E STOP IS DEPRESSED HED RESET BYPASS PRESS THE RELEASE BUTTON LEGEND O 5 RED 0 9 First number indicates PLC output lights second tell s output light that s activated 4111 0016 January 2014 PLACECARD Placard Installation Instructions Owner is responsible for the installation and placement of product placards Make sure placard is in plain view of dock leveler operations Suggested pl
50. rea is clear Operate the vehicle restraint thru one complete cycle inspecting it for proper operation and light sequence Advise maintenance personnel of any damage or improper operation immediately Remove all malfunctioning or damaged vehicle restraints from service using approved lockout tagout procedures 2 Before attempting to restrain a transport vehicle e Verify that transport vehicle is positioned squarely against dock bumpers nspect the transport vehicle s rear impact guard RIG Damaged or missing RIGs may not allow the vehicle restraint to securely capture the RIG Wheel chocks must be used whenever the ability for the vehicle restraint to capture the RIG is in question NOTE The transport vehicle s suspension and load condition will effect trailer height 3 Afteractivating vehicle restraint Verify that the transport vehicle s RIG has been restrained successfully In the event this cannot be determined use wheel chocks in addition to restraint f equipped with a light communication package load and unload on GREEN light only 4 Maintenance or service must be performed by authorized personnel only Follow approved lockout tagout procedures FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DEATH OR OTHER SERIOUS INJURY AE xus 1 262 255 1510 or 1 800 643 5424 MCGUIRE DLM Call for additional placards or manuals or with questions SYSTEMS INC regarding proper use maintenance and repair of dock level
51. restraint lights work Weekly Maintenance Operate the PowerHold vehicle restraint through the complete operating cycle to maintain lubrication NOTE position Apply lubricant e Inspect the slide block track and push rod areas The areas must be kept free of dirt and debris Build up of foreign material in the track areas will cause abnormal operation Quarterly Maintenance e Clean and Lubricate slide block track and push rod areas Lubricate pins for the Z bar Inspect and clean Prox switches Yearly Maintenance e Repeat of Quarterly Maintenance e Change Hydraulic Oil May be required earlier depending on conditions 4111 0016 January 2014 19 MAINTENANCE Periodic Maintenance With Leveler A Lip Hinge Area B Valve Lever Pivot on Logic E Platform Hinge Area Block F Frame Cylinder Trunnion C Inspection Plate Before performing any maintenance under the dock leveler lock the electrical power source in OFF position and lock the maintenance prop in the service position using an approved locking device See Service Dock Leveler Safely in this section Failure to follow these instructions may result in serious personal injury or death IMPORTANT Use of fluids that do not have equivalent specifications to those in the following list will result in abnormal operation of the dock leveler and voiding of warranty 20 G Toe Guard Hinges H Platform Cylinder to Platfo
52. rm Pin J Lip Cylinder to Platform Pin D Dual Lanyard Lever Pivot On select models an inspection plate is provided in the platform floor for ease of maintenance and pit inspection Others must be serviced from under the leveler K Lip Lifter and Lip Cylinder Pin L Toe Guard cams To ensure normal operation of the restraint or dock leveler use only aircraft hydraulic fluid designed to meet or exceed military specification MIL H 5606 G It is recommended that the following hydraulic fluids be used e ULTRA VIS HVI 15 e Aero Shell Fluid 4 or Fluid 41 e Mobile Aero HFA Mil H5606A or Aero HF e Texaco Aircraft Hydraulic Oil 15 or 5606 e Exxon Univis J13 These fluid brands can be mixed together Mixing with fluids that do not meet or exceed MIL H 5606 G may damage the equipment and WILL void warranty Use of hydraulic fluids with equivalent specifications to those listed here are acceptable 4111 0016 January 2014 Daily Maintenance e Make sure that all the Inside and Outside signal lights work Weekly Maintenance e Operate the dock leveler and PowerHold through the complete operating cycle to maintain lubrication NOTE To thoroughly inspect the platform hinge area put the platform in the full below dock position Inspect the platform hinge and the lip hinge areas The hinge areas must be kept free of dirt and debris Build up of foreign material in the hinge areas will cause abnormal oper
53. rt Symbol identifies important safety messages on equipment safety signs in manuals or elsewhere When you see this symbol be alert to the possibility of personal injury or death Follow the instructions in the safety message The use of the word DANGER signifies the presence of an extreme hazard or unsafe practice which will most likely result in severe injury or death The use of the word WARNING signifies the presence of a serious hazard or unsafe practice which may result in serious injury or death The use of the word CAUTION signifies possible hazard or unsafe practice which could result in personal injury IMPORTANT The use of the word IMPORTANT is to draw attention to a procedure that needs to be followed to prevent machine damage 4111 0016 January 2014 SAFETY General Operational Safety Precautions Head and understand the operating instructions and become thoroughly familiar with the equipment and its controls before operating the dock leveler Never operate a dock leveler while a safety device or guard is removed or disconnected Never remove DANGER WARNING or CAUTION signs or decals on the equipment unless replacing them Do not start the equipment until all unauthorized personnel in the area have been warned and have moved outside the operating zone Hemove any tools or foreign objects from the operating zone before starting Keep the operating zone free of obstacles that
54. rt vehicle RIG bar Raise the dock by pressing the RAISE button until the lip is fully extended Release the RAISE button The leveler will drop to the floor of the transport vehicle If a RIG test fixture is used it should allow the leveler to drop to the full below dock position without the contact between the lip and test fixture 4111 0016 January 2014 Keeper 6 Press the RELEASE button The vehicle restraint should NOT disengage from the transport vehicle HIG bar or test fixture If the vehicle restraint did NOT engage proceed with step 7 If the vehicle restraint DID disengage move the switch farther from the target or bend the target so that the target is not in the sensing range of the switch as shown in Figure 37 Make adjustments at switch and or target until vehicle restraint does not disengage transport vehicle IMPORTANT If adjustments are required in this step make sure that the interlocking described in step 3 is still in effect after step 6 adjustments are complete Press the RAISE push button The dock leveler will raise The leveler lip will fold as the platform raises When the lip is fully folded release the RAISE push button The leveler will descend to the cross traffic position Momentarily press the RELEASE button The vehicle restraint will return to the stored position 25 OPTIONAL EQUIPMENT ADJUSTMENTS Adjust Auto Return To Dock ARTD A Cable E Target B
55. temsInc com 4111 0016 January 2014 11 INSTALLATION Component Identification A Weldment E Valve Block H Slide Block B Latch Assembly F Shoe Push Rod C Hydraulic Cylinder G Rack Weldment J Spring D Power Pack SC Only TWIDO Programmable Logic Controller 12 4111 0016 January 2014 INSTALLATION Component Identification PowerHold manifold with leveler hose connections Diverter valve When coil is energized directs fluid to the PowerHold Q z SY HS Pressure To Logic Block Pressure From Pump Return To Pump Return To Logic Block 4111 0016 January 2014 13 OPERATION Operating Instructions Stay clear of dock leveler when transport vehicle DO NOT overload the dock Leveler carrier is entering or leaving dock area DO NOT operate any equipment while under the DO NOT move or use the dock leveler if anyone is influence of alcohol or drugs under or in front of leveler DO NOT leave equipment or material unattended Keep hands and feet clear of pinch points Avoid on the dock leveler putting any part of your body near moving parts Failure to follow these instructions may result in Failure to follow these instructions may result in personal injury and or damage to equipment severe personal injury or death Only trained personnel should operate the dock leveler and vehicle restraint 44 DANGER DO NOT use a broken or damaged dock leveler
56. ure line to line voltage at load side of starter Combination Lavelerand Line side and load side voltages should be P Hold Only approximately the same Replace starter if voltage values are considerably different from one another Check all wiring to motor for high resistance or no connection Replace motor NOTE A motor that is If motor hums but does missing voltage on one line not run overload device s said to be single phased should trip Three phase units only Phase reversed Heverse any two legs at the branch circuit Restraint does not disconnect operate Motor runs in reverse Single phase units only Line voltage too low Check wiring to motor for high resistance Check for Restraint does not loose or corroded connections Check if gauge of operate wires to motor are of correct size and specification for load requirement Replace if necessary Motor energizes but does not run Defective motor centrifugal Replace motor switch Defective motor capacitor Replace motor Low hydraulic fluid Add fluid see Maintenance section for proper fluid level and type Low hydraulic fluid Add fluid see Maintenance section for proper fluid level and type Restraint operates slowly Pressure relief valve set too See pressure relief adjustments on page 48 low combination unit only The pressure relief valve must not be set at a level that causes the motor operating current to exceed the full
57. ve NOTE Do not over tighten valve into block Max Torque 10 15 Ib ft or snug to prevent leakage Tighten coil snug avoid over tightening and causing valve to bind Operate unit Replace valve if problem persists and all other troubleshooting procedures Locate solenoid See Page 48 Coil must be energized when P Hold is in engage or disengaged Check valve for Magnetism at the coil Remove coil from cartridge valve and cartridge valve from valve block Check valve for contaminant s and or damage Replace valve if damaged Carefully wipe valve with clean rag do not damage O rings on valve Check valve block for contaminants Replace valve and coil NOTE Do not over tighten valve into block Max Torque 10 15 Ib ft or snug to prevent leakage Tighten coil snug avoid over tightening and causing valve to bind Operate unit Replace valve if problem persists and all other troubleshooting procedures performed 4111 0016 January 2014 TROUBLE SHOOTING POWERHOLD Improper location of P Hold Power Hold must have a 4 set back from bumper SEE page 10 Restraint raises makes contact with ICC bar but does not lock Then returns to stored position Prox switch 1 Check prox switch 1 and 2 When metal is placed in front of prox the led light on the prox will light up When the led on the prox is lit the inputs 3 and 4 on the plc will also be lit Shorted or open prox switch open or shorted w
58. vel and type Platform DOES rise to full Low hydraulic fluid Add fluid see Maintenance section for proper fluid height but lip DOES NOT level and type extend or extend fully Logic block valve lever Adjust cable weight See Adjust Cable Weight and cable weight too low on Down Speed Control in the Adjustment section cable 34 4111 0016 January 2014 TROUBLESHOOTING DOCK LEVELER Symptom PossibieCause Seen Platform locks into Platform lowering speed is Adjust platform down speed control safety as platform too fast lowers Lip drops to See Adjust Cable Weight and Down Speed Control vertical position in the Adjustment section NOTE Extreme cold weather OR incorrect fluid may cause platform to lock Adjustment is same Dock leveler equipped The auto return proximity Adjust proximity switch and target as necessary with ARTD Platform switch not sensing target oee Adjust Auto Return To Dock ARTD in the does not automatically correctly Adjustment section return to the cross traffic position or operates Defective proximity switch Replace switch abnormally Broken wire Loose or Repair or replace wires and connections as corroded wire connections necessary Lights flash but don t Stored prox switch Check input 13 on PLC If 13 is on light will state be Red inside and Green outside check for damaged switch or wire connections Red lights flashing Stored prox Switch Restrai

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